Waterproof shoe construction

ABSTRACT

An inner liner is provided for a shoe that makes the shoe waterproof and at the same time allows the foot to breathe. To accomplish this purpose, such a liner is constructed of a material that is impervious to water but is pervious to perspiration vapors. The liner comprises a sock-like configuration shaped to fit within a shoe upper and attached to the top and bottom portions of the upper, such liner having fold portions similar to fold portions at the front of the shoe to allow expansion and contraction thereof when the shoe is placed on the foot and removed. The liner may also employ a novel seam in joined portions thereof, and its particular structure allows it to be combined with all conventional types of shoe constructions.

.Iadd.This is a continuation of application Ser. No. 07/646,828, filedon Jan. 25, 1991, now abandoned, .Iaddend. .[.This application.]..Iadd.which .Iaddend.is a continuation of U.S. application Ser. No.290,485, filed 8/6/81 now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to new and useful improvements in shoeconstructions and is particularly concerned with a waterproof shoeconstruction.

It is well known that leather shoes without special treatment allowpenetration of outside moisture into the interior of the shoe and thusthe feet will eventually get wet. This is because of the porous natureof leather and also because of stitching through the leather layers toaccomplish the form fitting shoe construction. Leather shoes haveheretofore been waterproofed by applications of oil, wax, latex orrubber or other waterproofing substances and while such waterproofingtechniques close the pores of the leather, they cannot completely closethe stitching holes resulting from the attachment of the sole and upperportions. Furthermore, the waterproofing treatment of the shoe does notallow the foot to breathe whereby perspiration vapors condense andmoisture gathers around the foot. Other types of shoes have beenprovided that are completely waterproof, such as rubber or plasticshoes, but here again the feet cannot breathe and such shoes aregenerally uncomfortable and unhealthy in their use. Also, this lattertype of shoe is not repairable.

SUMMARY OF THE INVENTION

According to the present invention and forming a primary objectivethereof, a shoe construction is provided that is impervious to water butpervious to perspiration vapors whereby to provide a waterproofconstruction but one which allows the foot to breathe.

A more particular object of the invention is to provide a shoeconstruction having an inner liner with a novel construction to providesuch waterproof and ventilating capabilities and also to make awaterproof shoe that is repairable.

A further object is to provide a liner of the type described which has anovel shape whereby to be secured within a shoe and to provide frontexpansion similar to that of the tongue portion of the shoe forinsertion and removal of the foot.

Another object of the invention is to provide a shoe liner of the typedescribed which is light in weight, comfortable to the foot, and ruggedin use. The liner, due to its waterproofing characteristics allows otherportions of the shoe to be constructed of lightweight material, thusreducing the over-all weight of the shoe.

A further object is to provide a shoe liner of the type described havinga novel seam connection which, upon the application of heat, sealsoverlapping layers together in a waterproof connection. If stitching isused in such seam, the seam connection also waterproofs the area aroundthe stitching.

Still another object of the invention is to provide a waterproof shoeliner that is adaptable for use with substantially all existing types ofshoe constructions. Furthermore the liner allows the shoe to be re-soledby a repairman without damaging the waterproof liner.

In carrying out the objectives of the invention, the shoe of theinvention has an inner liner, with a specific construction adapting itto fit the inner contour of the shoe. It has fold portions correspondingto the front tongue fold portions of a shoe to allow expansion andcontraction for inserting and removing the shoe on the foot and forlacing it in place. The liner is made from a material which isimpervious to water but which is pervious to perspiration vapors. It issock-like in its shape and may include either a complete enclosure witha full bottom wall or it may include only a partial bottom wall withwaterproof sealing engagement on the sole. Seams on the liner arewaterproofed by heat treating the material of the liner and/or anadhesively backed tape, or by other methods such as electro die heatsealing.

The invention will be better understood and additional objects andadvantages will become apparent from the following description taken inconnection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shoe construction of the type withwhich the present invention may be combined;

FIG. 2 is a perspective view of a liner of the instant invention shownapart from the shoe;

FIG. 3 is an enlarged fragmentary sectional view taken on the line 3--3of FIG. 1 and showing the liner in the shoe;

FIGS. 4 and 5 are enlarged fragmentary sectional views showing theformation of a seam in the liner of FIG. 2, such views being taken onthe line 4--4 of FIG. 2 and comprising respectively an initial lay-up ofthe seam in its construction and the finished seam;

FIG. 6 is an enlarged fragmentary sectional view taken on the line 6--6of FIG. 1;

FIG. 7 is an enlarged sectional view taken on the line 7--7 of FIG. 1;

FIG. 8 is an enlarged sectional view similar to FIG. 3 but showing amodified form of the liner of FIG. 2;

FIG. 9 is a fragmentary sectional view of a modified shoe constructionutilizing the present invention; and

FIGS. 10, 11, 12, 13 and 14 are fragmentary sectional views takensimilar to FIG. 9 and showing application of the present invention tovarious types of conventional shoe constructions.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With particular reference to the drawings, and first to FIGS. 1, 3, 6and 7, the present invention is designed for use with shoe constructionshaving a foot receiving portion 10, referred to as the upper, an outsole12, a midsole 14, and an insole 16. Although shoe constructions mayvary, the midsole 14 is shown herein as adhesively secured to theoutsole 12, and the upper 10 is secured to the midsole 14 by an outsidestitchdown 18. The shoe of FIG. 1 has conventional front lacing 20engageable in eyelets 22. The shoe also has a tongue portion 24 securedat the sides to the shoe and provided with fold portions 24a which allowfor expansion and contraction of the shoe upper for insertion andremoval of the foot and for lacing the shoe on the foot. A topconnecting strip piece or cap 26 is doubled over the top of the upperand secured in place by stitching 26a. The shoe may have side cutoutportions covered with a lightweight flexible material 28 such as fabric,thin leather, etc. secured to main leather portions of the shoe andprovided for the purpose of reducing the weight of the shoe. The shoemay also have suitable conventional lining and padding 30.

The waterproofing structure of the invention is designed to be combinedwith the shoe just described or various other types of shoe to bedescribed hereinafter, and serves not only to provide water protectionfor the foot but also to allow the foot to breathe. Such inventioncomprises a sock-like liner 32. FIG. 2, having an open top 34 and in theembodiment of FIG. 2 having a full bottom wall 36 forming a completeenclosure except for the top. The liner is made to conform to the shapeand size of the interior of the shoe and includes a front tongue portion38 having fold portions 38e. The fold portions 38a of the liner conformin shape to the fold portions 26a of the shoe and thus all of such foldportions expand and contract together for insertion and removal of thefoot.

With the liner 32 mounted in the shoe, FIGS. 3, 6 and 7, the bottom wall36 thereof seats on the midsole 14 and is adhesively secured thereto.The thickness of the shoe layers, particularly the liner 32, in thesection views of FIGS. 3, 6 and 7, is exaggerated for illustrationpurposes. The insole 16 is supported on the bottom wall 36 of the liner32 and is adhesively secured thereto. The upper end 34 of the liner, asbest seen in FIG. 6, is secured to the top trim piece 26 by thestitching 26a. The only points of attachment of the liner to the shoecomprise its stitched connection to the top trim piece 26, which isabove desired waterproofing portions of the shoe, and to the midsole 14which comprises an adhesive, non-stitched connection. It is to beunderstood that the liner 32 need not be stitched at the top to theupper as shown but could as well be adhesively secured in place orsuspended in the shoe by other means.

The liner 32 in its over-all construction provides the waterproofing ofthe shoe and is shown in enlarged section in FIGS. 4 and 5. It comprisesa novel combination of layers and their construction, comprising aninner or first layer of material 46 and exterior layers 48 and 50 allsecured together in laminated form by a waterproof thermoplastic resinadhesive. Layer 46 is constructed of a material which is impervious towater but pervious to perspiration vapors. This layer thus provides thewaterproofing but at the same time allows the foot to breathe. Arepresentative product having the features described for such materialis a product identified on the market by the trademark GORE-TEXmanufactured by W. L. Gore and Associates, Inc. This product comprises avery thin sheeting of thermoplastic resin substance that in itsmanufacture has the characteristic that is porous to the extent that itis impervious to water but pervious to vapors such as perspirationvapors. It has a melting point of 400° C.

.Iadd.The very thin sheeting of thermoplastic resin substance of theproduct identified by the trademark GORE-TEX is a microporous polymericfilm of polytetrafluoroethylene (PTFE). Gohlke and Tanner, GORE-TEX®Waterproof Breathable Laminates, J. Coated Fabrics, Vol. 6, 28 (July1976)..Iaddend.Layers 48 and 50 comprise protective layers of abrasionresistant, rugged and porous material. Also, the material from whichthese exterior layers is constructed, at least the outer layer 48,namely, the layer which is next to the shoe upper 10, is also athermoplastic resin substance. Layers 48 and 50 may thus simply comprisea woven or other porous type plastic structure having the abovecharacteristics. The inside layer 50 must also, of course, have asurface texture which does not cause foot discomfort. A representativeproduct for the layer 48 is a product identified on the market as Nexismanufactured by Burlington Corporation. It has a melting point of 225°C. The layer 50 is a product identified on the market as Cambrella,manufactured by Faxtex Corporation. It has a melting point of 250° C.This particular combination of materials or equivalent materials providea liner of the desired characteristics and furthermore are adaptable tothe formation of seams which in a best mode of manufacture may berequired, as will now be detailed.

Such a seam is designated by the numeral 52 in FIG. 2 and has aparticular structure that provides a strong and waterproof connection.The construction of the seam 52 is illustrated in detail in FIGS. 4 and5. As noted above, the thickness of the layers 46, 48 and 50 in theseviews, as well as other layers to be described, are greatly exaggeratedfor purposes of clarity. The actual thickness of the liner wall will forexample be around one thirty-seconds of an inch thick or less and notmaterially thicker at the seam 52.

With reference first to FIG. 4, which shows the initial lay-up of theseam in its construction, end portions 32a of the liner which are to besecured together are laid in overlapping relation and stitched togetherby stitching 54. The seam is covered with tape 55 having a main bodyportion 56 of tough high tensile strength material such as Nylon andhaving a melting point of at least 250° C. A layer 57 of material whichis impervious to water but pervious to perspiration is laminated to mainbody portion 56 by a suitable thermoplastic resin adhesive. Layer 57 maycomprises Gore-Tex similar to layer 46 in the liner 32, it being desiredthat it have a higher melting point than layer 48. The layer 57 has anadhesive coating 58 on its exposed surface, such adhesive comprising athermoplastic resin adhesive. It is desired that this adhesive coatingas well as the adhesive used in the lamination of the layers 46, 48 and50 and layers 56 and 57 comprise a thermoplastic resin adhesive have amelting point of 225° C. or slightly less.

With the tape laid over the overlapped portions 32a of the liner, heatand pressure are then applied to the seam with the heat being applied onthe tape side. The heat applied is preselected whereby to soften thelayers 48 as well as the adhesive between the layers 46, 48 and 50 andthe tape adhesive 58 but not to soften layers 46, 50, 56 and 57. Thus, atemperature in the range above 225° C. but below 250° C. is used. Arepresentative pressure is 120 psi. By such process, a solid structuralwaterproof weld 60, FIG. 5, is provided into and including at least aportion of the depth into waterproof layers 46, namely, a penetratingdistance shown by arrows 62 in FIG. 5. More particularly, the tape 55,particularly its Gore-Tex layer 57, is welded to both layers 48, and thelayers 48 are welded to their respective waterproofing layers 46. Bysuch structure, the stitching 54 is completely covered by waterproofingmaterial and the end edges of the outside end portions 32a are sealed.In a broad sense selected materials for the layers of the liner as wellas adhesive layers are used with selected heat and pressure valuesrelated to the melting point of such materials whereby such layers andadhesive form a weld from the layer 57 in the tape down to and includinglayers 46 on both overlapping ends 32a.

It is to be understood that the seams 52 may be formed without stitching54 if desired such as by electro-die sealing and adhesives. It is alsoto be understood that other or differently placed seams may be requiredin the liner such as seams up the back and/or front.

With reference to FIG. 8, a somewhat modified form of liner 32' isprovided. The shoe structure 10 is identical to that shown in FIGS. 1,3, 6 and 7 but the liner 32' of the invention is modified to the extendthat the bottom wall 36' does not extend the full width and length ofthe liner but instead has inturned flange portions 64 at the sides andaround the front and rear. The bottom wall of this embodiment thus hasan opening 66. In this embodiment, the flange portions 64 arepermanently attached as by adhesive to the midsole 14 and to an insole16. The numeral 67 designates a shank of conventional use andconstruction. These shanks may be located in the shoe as required.

FIG. 9 illustrates an embodiment 10" of shoe construction also utilizingthe present principle. Such structure uses the waterproof liner of theinvention which may comprise the full bottom liner structure 32 as inFIG. 2, as shown, or it could as well comprise the open bottom liner 32'as in FIG. 8. In this embodiment, a lining 30 is disposed between thepresent liner 32 and the upper 10" and is turned inwardly a shortdistance across the sole. Lining 30 may also be turned outwardly as inFIG. 3, if desired. Also in the embodiment of FIG. 9, an additionalmidsole 68 may be provided under the lining 30 and insert 32.

Another feature of the present invention is that the insert structurecan be combined with various other types of shoe structures in commonuse. One such structure is shown in FIG. 10 and is known in the trade asthe Norwegian welt. Such structure employs an upper 70 and outsole 72,one or more midsoles 74, a lower insole 76 having an outer downturnedlip 78, and an insole 80. In this structure, the upper 70 is stitched tothe lip 78 of the insole 76 by stitching 82, and also has an outsidestitchdown 84. A liner 32' with the open bottom is readily applicable tothis conventional structure by fitting it within the shoe and securingit as in FIG. 8. A filler 86 may be used under the insole 76 if desired.

FIG. 11 also shows a Norwegian welt construction and is identical toFIG. 10 except that such construction is used in combination with theinsert 32 of the invention having the full bottom wall 36. Such fullbottom liner can be used with an upper insole.

FIG. 12 shows a liner 32' of the invention combined with anotherconventional shoe construction which is known in the trade as the LittleWay construction. The upper 90 of this shoe is turned in at the bottomand secured by an inside stitchdown 92 to a midsole 94 secured to anoutsole 96. The liner 32' is supported on and secured to a lower insole98 secured in place by the stitching 92. Liner 32 supports an upperinsole 100.

FIG. 13 shows a liner 32' of the invention in combination with yetanother conventional structure known in the trade as the Goodyear welt.In such structure, a horizontal stitching 104 secures the upper 106 to astrip 108 of welting and to a downturned lip 110 on a lower insole 112.The welting strip 108 is also secured by an outside stitchdown 114 to amidsole 116 in turn secured to outsole 118. Liner 32' seats on lowerinsole 112 and supports an upper insole 120.

FIG. 14 shows an injected molded welt wherein the upper 122 of leatheris injection molded to the outsole 124 to provide a waterproofconnection. The liner 32' of the invention is supported on the bottom ofthe shoe. Outsole 124 is suitably contoured at 126 for the intendedpurpose. An insole 128 is supported on the liner 32.

It will be seen by the above description that the present shoe liner hasthe distinct advantage of being capable of being combined with mostconventional type shoe constructions and furthermore is readily appliedto the shoe in its construction and readily replaceable if necessary. Inaddition to providing water protection from the outside but allowingvapor escape from the inside, the structure with the woven layers 48 and50 is comfortable to the feet. Such liner furthermore is inexpensive tomanufacture and thus does not add materially to the cost of the shoe. Inaddition the liner is light in weight and allows, such as by lightweightpanels 28, the over-all weight of the shoe to be reduced. The shoe solesin these repairable type constructions are repairable without damagingthe liner from the outside.

It is to be understood that the forms of my invention herein shown anddescribed are to be taken as preferred examples of the same and thatvarious changes in the shape, size and arrangement of parts may beresorted to without departing from the spirit of my invention, or thescope of the subjoined claims. For example, the liner may be installedin the shoe during the construction of the shoe or else it can beinstalled after the shoe is completed. In this latter instance, theliner is installed in a completed shoe by suitable attachment at the topconnecting strip and by adhesively securing it to the sole, as by aheating process.

Having thus described my invention, I claim:
 1. A shoe constructioncomprising:(a) a sole; (b) an integral upper having a bottom portionsecured to said sole, panel portions extending upwardly from said bottomportion, a tongue and gussets connecting said tongue to said panelportions, said upper including a top opening arranged to receive a footand defined by the edges remote from said sole of said panel portions,tongue and gussets; and (c) a .Iadd.separate .Iaddend.sock-like liner.Iadd.being a laminate of at least three layers, the outer layer thereofformed of porous, abrasion-resistant material, an intermediate layerbeing formed of sheeting of an effectively continuous layer ofthermoplastic resin material which is impervious to water but perviousto perspiration vapor and an inner layer formed of porous,abrasion-resistant material .Iaddend.disposed .Iadd.as an insert.Iaddend.in said upper, said liner .[.being formed of material which isimpervious of water, but pervious to perspiration vapor.]. .Iadd.forminga complete enclosure except for an open top thereof .Iaddend.and.Iadd.said sock liner having a front tongue and gussets portion toconform with said tongue and gussets, said liner .Iaddend.being securedto said upper only proximate the top opening thereof .Iadd.and therebyrendering the shoe waterproof to its wearer to the top opening.Iaddend..2. The shoe construction of claim 1 wherein said liner includes toe,heel, side .[.tongue, gusset.]. and bottom portions .[.and is open atthe top.]., the bottom portion of said liner being adhesively fixed tosaid sole. .[.
 3. The shoe construction of claim 2 wherein said bottomportion has a longitudinal opening and is adhesively fixed to adjacentsides of said sole..]. .[.4. The shoe construction of claim 2 whereinsaid bottom portion is fully closed..]. .[.5. The shoe construction ofclaim 1 wherein said liner comprises a first layer of material which isimpervious to water but pervious to perspiration vapors, and a secondlayer of porous protective material affixed to at least one side of saidfirst layer..]. The shoe construction of claim .[.5.]. .Iadd.1.Iaddend.wherein said .[.second.]. .Iadd.intermediate .Iaddend.layer isdisposed on the side of said .[.first.]. .Iadd.outer .Iaddend.layeradjacent said upper .[.and is formed of a thermoplastic resinmaterial.]. and wherein said liner includes a seam comprisingoverlapping portions thereof and stitching holding said overlappingportions together, a tape on said .[.second.]. .Iadd.intermediate.Iaddend.layer over said stitching, and an adhesive backing on said tapeof thermoplastic resin material, said seam being waterproofed at saidstitching by heat melting thermoplastic portions of said liner and tapeand forming a waterproof seal. .[.7. The shoe construction of claim 1wherein said liner comprises a first layer of material which isimpervious to water but pervious to perspiration vapors, and a secondlayer of porous protective material affixed to the side of said firstlayer adjacent the foot..]. .[.8. The shoe construction of claim 1wherein said liner comprises a laminated structure including a firstlayer of material which is impervious to water but pervious toperspiration vapors disposed between second and third layers of porousprotective material..]. .[.9. A shoe construction comprising:(a) a sole;(b) an integral upper having a bottom portion secured to said sole,panel portions extending upwardly from said bottom portion, a tongue andgussets connecting said tongue to said panel portions, said upperincluding a top opening arranged to receive a foot and defined by theedges remote from said sole of said panel portions, tongue and gussets;(c) a sock-like liner open at the top and including toe, heel, side,tongue, gusset and bottom portions, said liner being disposed in saidupper and being secured to said upper only proximate the top openingthereof and to said sole; and (d) said liner comprising laminated firstand second layers, said first layer being a material which is imperviousto water but pervious to perspiration vapor and said second layer beinga porous, protective material..]. .Iadd.10. The shoe construction ofclaim 1 wherein said liner is secured to said upper by stitching..Iaddend. .Iadd.11. The shoe construction of claim 1 wherein saidthermoplastic resin comprises microporous polytetrafluoroethylene..Iaddend. .Iadd.12. The shoe construction of claim 11 wherein saidmicroporous polytetrafluoroethylene is provided as a sheeting. .Iaddend..Iadd.13. The shoe construction of claim 2, wherein said thermoplasticresin comprises microporous polytetrafluoroethylene. .Iaddend. .Iadd.14.The shoe construction of claim 6, wherein said thermoplastic resincomprises microporous polytetrafluoroethylene. .Iaddend. .Iadd.15. Ashoe construction comprising:(a) a sole; (b) an integral upper having abottom portion secured to said sole, panel portions extending upwardlyfrom said bottom portion, a tongue and gussets connecting said tongue tosaid panel portions, said upper including a top opening arranged toreceive a foot and defined by the edges remote from said sole of saidpanel portions tongue and gussets: and (c) a separate sock-like linerbeing a laminate of at least three layers, the outer layer thereofformed of porous, abrasion-resistant material, an intermediate layerbeing formed of a sheeting of an effectively continuous layer ofthermoplastic resin material of microporous polytetrafluoroethylenewhich is impervious to water but pervious to perspiration vapor and aninner layer formed of porous, abrasion-resistant material disposed as aninsert in said upper, said liner forming a complete enclosure except foran open top thereof and said sock-like liner having a front tongue andgussets, said liner being secured by stitching to said upper proximateto the top opening thereof rendering the shoe waterproof to its wearerto the top opening, said liner further including toe, heel, side andbottom portions and in which said bottom liner portion is adhesivelyfixed to said sole, said liner including a seam with overlappingportions thereof and stitching holding said overlapping portionstogether, a tape on said intermediate layer over said stitching, and anadhesive backing on said tape of thermoplastic resin material, said seambeing waterproofed at said stitching by heat melting thermoplasticportions of said liner and tape forming a waterproof seal. .Iaddend.